Electronic devices and processes for forming the same

Abstract

An electronic device includes an array. In one embodiment, a process for forming an electronic device includes the array, which includes electronic components, can include printing one or more layers as a series of segments onto a workpiece. In one embodiment, a process includes printing a layer onto the workpiece and at least one exposed portion of the chuck. In still another embodiment, a printing head is greater than 0.5 mm from the workpiece. In a further embodiment, “hybrid” printing can be used to help form a thicker layer having a relatively thinner width. In a further embodiment, processes can be used to reduce the likelihood of a stitching defect, nonuniformity of a layer across an array, or a combination thereof. A printing apparatus can be modified to achieve more flexibility in liquid compositions, temperatures or other conditions used in printing a layer.

1 . A process for forming an electronic device comprising an array of electronic components, wherein the process comprises:
 placing a workpiece within a printing apparatus; and   continuously printing a first layer as a series of first segments onto the workpiece, wherein from a plan view within the array:
 each of the first segments has a first side and a second side opposite the first side; and 
 as each specific first segment is continuously printed:
 another first segment generates a significant amount of a first vapor and lies closer to the first side of the specific first segment compared to the second side of the specific first segment; and 
 for a first portion of the array lying along the second side of the specific first segment, the first portion does not include any other first segment that generates a significant amount of the first vapor. 
 
   
     
     
         2 . The process of  claim 1 , wherein continuously printing is performed such that only one first segment is printed at a time. 
     
     
         3 . The process of  claim 1 , wherein the process further comprises:
 continuously printing a second layer as a series of second segments onto the workpiece, wherein the second layer has a different composition compared to the first layer, and from a plan view within the array:
 each of the second segments has a first side and a second side opposite the first side; and 
 as each specific second segment is continuously printed:
 another second segment generates a significant amount of a second vapor and lies closer to the first side of the specific second segment compared to the second side of the specific second segment; and 
 for a second portion of the array lying along the second side of the specific second segment, the second portion does not include any other second segment that generates a significant amount of the second vapor; and 
 
   continuously printing a third layer as a series of third segments onto the workpiece, wherein the third layer has a different composition compared to each of the first and second layers, and from a plan view within the array:
 each of the third segments has a first side and a second side opposite the first side; and 
 as each specific third segment is continuously printed:
 another third segment generates a significant amount of a third vapor and lies closer to the first side of the specific third segment compared to the second side of the specific third segment; and 
 for a third portion of the array lying on the second side of the specific third segment, the third portion does not include any other third segment that generates a significant amount of the third vapor. 
 
   
     
     
         4 . The process of  claim 3 , wherein continuously printing is performed such that no more than only one first segment, only one second segment, and only one third segment are continuously printed simultaneously. 
     
     
         5 . The process of  claim 3 , wherein:
 the first layer is a blue light-emitting layer;   the second layer is a green light-emitting layer; and   the third layer is a red light-emitting layer.   
     
     
         6 . The process of  claim 1 , wherein a set of the first segments is printed as dummy segments before reaching the array and after printing over the array. 
     
     
         7 . The process of  claim 1 , wherein:
 the electronic device comprises an electronic component;   the electronic component comprises an organic active layer; and   the organic active layer comprises the first layer.